Balanced and integrated chassis and floor system for mobile home and modular units

ABSTRACT

An integrated chassis and floor system for mobile homes and the like utilizes a pair of widely spaced, elongate flanged frame beams constituting the exterior sides of the chassis as well as a floor system integrated therewith. The heavier frame beams are transversely interconnected by a multiplicity of spacing and reinforcing sections having vertically disposed intermediate webs and upper and lower angular flanges, said lower flanges serving as supports for a lower horizontal floor partition &#39;&#39;&#39;&#39;skin&#39;&#39;&#39;&#39; medium. A stratum of strong plastic material such as urethane is laid up against and above said &#39;&#39;&#39;&#39;skin&#39;&#39;&#39;&#39; and extends into the longitudinal frame beams, integrating said transverse sections and sealing the lower floor section of said system with said longitudinal beams. Upper horizontal flooring sections (one or two layers of flooring) are supported upon and interconnected with the upper angle flanges of said transverse sections and serve to further integrate the entire flooring and chassis system. The said transverse sections have at least one set of substantially aligned, large apertures formed therethrough for intercommunicating plenums formed in said flooring system and for also, with freedom of sloping from the horizontal, accommodating conduits for drain and plumbing. Preferably media are provided by for example, smaller holes at the sides of said apertures to accommodate and fasten strap or hanger members for supporting such ducts. One or more sets of longitudinally extending sections, constructed of the same kind of material as the transverse reinforcing sections, are medially disposed within the floor system traversing said first reinforcing sections and having the multi-functions of further reinforcing the entire floor and chassis system and further dividing the transverse plenums between the upper and lower flooring sections to define intake and return ducts or the like for air conditioning and heating.

v United States Patent [191 Paulson 1 Feb. 19, B974 BALANCED ANDINTEGRATED CHASSIS AND FLOOR SYSTEM FOR MOBILE HOME AND MODULAR UNITS[76] lnventor: Orville B. Paulson, 838 E. Sierra Madre, Glendora, Calif.91740 22 Filed: Sept. 28, 1972 [21] Appl. No.: 293,153

Primary ExaminerDavid Schonberg Assistant Examiner--John A. PekarAttorney, Agent, or Firm-Williamson, Bains & Moore [5 7 ABSTRACT Anintegrated chassis and floor system for mobile homes and the likeutilizes a pair of widely spaced, elongate flanged frame beamsconstituting the exterior sides of the chassis as well as a floor systemintegrated therewith. The heavier frame beams are transverselyinterconnected by a multiplicity of spacing and reinforcing sectionshaving vertically disposed intermediate webs and upper and lower angularflanges, said lower flanges serving as supports for a lower horizontalfloor partition skin medium. A stratum of strong plastic material suchas urethane is laid up against and above said skin and extends into thelongitudinal frame beams, integrating said transverse sections andsealing the lower floor section of said system with said longitudinalbeams. Upper horizontal flooring sections (one or two layers offlooring) are supported upon and interconnected with the upper angleflanges of said transverse sections and serve to further integrate theentire flooring and chassis system. The said transverse sections have atleast one set of substantially aligned, large apertures formedtherethrough for intercommunicating plenums formed in said flooringsystem and for also, with freedom of sloping from the horizontal,accommodating conduits for drain and plumbing. Preferably media areprovided by for example, smaller holes at the sides of said apertures toaccommodate and fasten strap or hanger members for supporting suchducts. One or more sets of longitudinally extending sections,constructed of the same kind of material as the transverse reinforcingsections, are medially disposed within the floor system traversing saidfirst reinforcing sections and having the multifunctions of furtherreinforcing the entire floor and chassis system and further dividing thetransverse plenums between the upper and lower flooring sections todefine intake and return ducts or the like for air conditioning andheating.

8 Claims, 7 Drawing Figures PATENTEB FEB] 9 I974 SHEET 1 OF 2 {F rillfliQ 1 PATENIEQFEB 1 9:914

' sum 2 or 2 BALANCED AND INTEGRATED CHASSIS AND FLOOR SYSTEM FOR MOBILEHOME AND MODULAR UNITS BACKGROUND OF INVENTION The mobile home industryhas achieved significant success in producing lower cost housing and inreducing taxes to home owners through the use and rental of property fortemporarily or permanently positioning mobile homes. Modular housing andits principles are now being extensively applied and will, in thefuture, supersede to a substantial extent, conventional buildings forhomes and housing units. Major improvements in the design, economy andprocess of manufacture or assembly of mobile homes and modular units, inmy opinion, should materially benefit the housing industry as a whole.

The present day floor and chassis systems and construction for mobilehomes and for modular units conventionally employ a multiplicity of woodor metal joists spaced about sixteen inches apart over a steel chassisframe to obtain adequate strength and rigidity of purpose of the systemor unit. The main beams of the chassis or support are usually disposedinwardly of the longitudinal sides of the construction rather than atthe peripheral or perimeter edges thereof and are not integrated toperform multiple functions with the flooring system. i

To obtain proper spacing between the flooring sections proper and alower sealed bottom floor partition, the said joists must be relativelywide so that adequate space for receiving air conditioning ducts, drainpipes and plumbing, may be provided. In the assembly or building ofmobile homes, present day methods almost universally require the chassisof the mobile vehicle to be inverted and thereafter the laying-out ofthe joist floor is accomplished on the inverted unit, requiringsubsequent fastening of the joist floor to the unit and then requiringinversion of the complete assembly back to normal position. The heavy,relatively wide joist members must be cut or designed and spaced toallow intercommunication between plenums formed beneath the top flooringpartition and the overall width of the joists and thickness of upper andlower floor partitions cause the center of gravity in the finishedflooring system to be relatively high above the ground or othersupporting medium for the wheels.

UNDERLYING PRINCIPLES OF MY INVENTION A fundamental principle of myinvention and the main object thereofis to minimize the number ofessential components for an integrated chassis frame and flooring systemby causing all essential components to serve as many different functionsas possible in such integrated construction. I employ longitudinalchassis beams disposed at the outside longitudinal perimeters of myfloor system and serving in the dual function of constituting theperimeter frame for the floor as well as the main beams of the chassissystem.

In close cooperating relation with said structure I employ amultiplicity of transverse spacing and reinforcing sections spanningsaid side beams and interconnecting the same, and having verticallydisposed intermediate webs and upper and lower angular flanges.Conventional light gauge zee bars may be employed or other strips orsections having angled or T-flanges on the upper and lower edgesthereof. These sections are disposed across the shortest section of thefloor system interconnected at their ends with the chassis frame membersand the lower flanges thereof support a skin" or closure board uponwhich is laid up a heavy stratum of a strong plastic mat erial such asurethane which seals the entire bottom partition of the flooring systemwith the longitudinal beams of the chassis to greatly strengthen theentire construction.

The multiplicity of zee bars or other flanged sections have preferablytwo or more sets of aligned, large accommodation apertures forintercommunicating the plenums formed below the upper flooring, andfurther, for accommodating ducts and conduits for drains, plumbing, etc.The upper flooring material in one or two layers is supported upon andinterconnected with the upper flanges of the transverse spacing andreinforcing sections or zee bars. One or more longitudinally extendingflange sections are preferably employed to define multi-way ducts forflow of air.

I further prefer to provide in said transverse sections adjacent thelarge apertures means for readily securing hanger straps or the like forsupporting ducts and conduits in a desired longitudinal sloping relationas required.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF INVENTION In theaccompanying drawings, wherein like reference characters refer tosimilar parts throughout the several views: I

FIG. 1 is a top plan view with vertical walls and top removed, of thefloor system of my invention, some portions being broken away to showunderlying parts;

FIG. 2 is a cross section taken on the line 22 of FIG. 1 looking in thedirection of the arrows;

FIG. 3 is a cross section taken on the line 3-3 of FIG. 1 showing thereinforced portion of one of the framing structures of the systemsurrounding the trailer wheels and connection of the chassis and floorsystem with the springs of the chassis;

FIG. 4 is a vertical section taken on the line 4--4 of FIG. 2 andwherein is mounted the forward end of a plumbing drain pipe connectedwith atoilet bowl;

FIG. 5 is a cross section taken on the line 5-5 of FIG. 1 showing alongitudinally disposed divider and reinforcing strip for definingplenums and intercommunication for withdraw] of air in the airconditioning system;

FIG. 6 is a fragmentary top plan view of the forward portion of thefloor system on a much larger scale than that of FIG. 1, having portionsbroken away to show interior construction; and

FIG. 7 is a vertical section taken through approximately one half of acompleted mobile home showing by arrows circulation of warmed or cooledair with intake and return registers and ducts formed and divided by alongitudinal zee-bar or webbed section.

As shown in the drawings, an integrated floor and chassis system formobile homes and the like is illustrated having as the main frame forthe chassis and serving the secondary important function of constitutingthe perimeter frame for the floor unit, an assembly indicated as anentirety by the letter F. Assembly F comprises two heavy longitudinalchannel or I-beam members 10 having upper and lower angular flange lips10a and 10b, respectively. said members being spaced apart the totalwidth of the mobile home and chassis. As shown, a pair of heavy draftbeams 11 are connected at their rearward ends to the forward ends offrame members 10 and converge and are interconnected at their forwardends with a draft tongue 12 by which the mobile home or trailer may bepulled by connection with a motor vehicle.

My integrated and reinforced floor system spans and is interconnectedwith the longitudinal frame members 10, and inherently comprises amultiplicity of relatively light metal transverse sections 13, which maybe in the form of light gauge zee bars, sheet metal channels, or theequivalent, having central vertical webs 13a, lower angled horizontalflanges 13b, and upper angled horizontal flanges 13c. These transversesections span and interconnect the two longitudinal heavy frame channelsl and are interconnected with the flanges thereof by suitable means suchas welding, drive screws or the like.

The lower flanges 13b of said transverse sections support and areattached to thin partitions or supporting skins 14 which may constitutepre-cut sections of sheet metal or hard sheet plastic materials. Theskins preferably extend across all of the transverse sections 13 for thefull area of the lower partition of the floor assembly and arepreferably supported at their peripheral edges upon the lower flanges13b and the lower flanges b of the frame.

Upon the skin 14, which is spaced below the entire upper flooringstratum of my system, I form by lay-up or otherwise a relatively thickstratum of hard plastic material 15, such as foamed urethane, which hastensile strength and heat-insulating qualities and which preferably, asshown in FIGS. 2 and 3, in its formation is extended upwardly (pan-like)to provide side portions 15a which are disposed and at least partiallyfill the inwardly disposed channels defined by the longitudinal mainframe members 10. By this method a very durable and impervious shell andbottom floor partition is produced which embeds the lower flanges 13band upstanding central webs 13a of the interconnecting sections 13.

The upper floor stratum constitutes one or more layers of flooringmaterial 16 which is supported upon and covers the upper flanges 13c ofthe multiplicity of transverse reinforcing sections 13, and the sectionif made of a multiplicity of pieces, have the longitudinal edges of thepieces tongued and grooved or otherwise sealed to form an integratedsealed upper floor partition 16.

It will be seen that between the upper and lower horizontal partitionsof the floor assembly the vertical webs of the reinforcing transversesections 13 divide the interior into a multiplicity of separate plenums.These plenums are intercommunicated by a plurality of sets ofcommunication apertures 13x formed through the vertical webs 13a of thesections with the corresponding sets in the several sections beingaxially aligned longitudinally of the floor structure. The sections 13constituting the forward and rear ends of the floor system are of courseimperforate to form sealed ends for the floor system.

As shown in FIG. 5 and indicated by heavy broken lines in FIG. 1, one ormore longitudinal sections 17 of light gauge material similar in crosssectional shape to that of the transverse sections 13, extend mediallyand longitudinally of the double spaced floor structure and are securedand integrated with bottom stratum l5 and the upper flooring layer 16similarly to the cross sections 13. These sections with sealedinterconnection at their upper and lower flanges define longitudinal airand space dividers within the double partition floor systems, whichdividers may either be apertured near their forward and/or rear ends, orat other desirable locations to interconnect with a plenum or plenums onthe lateral sides thereof. Thus a duct system is provided for airconditioning, heating or the like due to the dual functions of thetransverse reinforcing and divider sections 13 and the longitudinaldivider sections 17.

Referring again to the apertures 131' formed in the transverselydisposed divider sections 13, I prefer to form the communicationapertures as large as possible consistent with the needed strength ofthe central webs 13a so that in addition to the communication betweentransverse plenums formed in my floor system space is provided foraccommodating ducts or pipes which extend longitudinally within thehollow floor system. Since the apertures 13x are of substantial diameterdrain and plumbing pipes P may slope from the forward portion of theframe and floor system rearwardly and may be successively supported onhanger straps or rods 18. In this connection I prefer to providehangerretaining elements inherently provided by portions of the sections13 adjacent the apertures 13x, such as the small apertures 13y whichwill accommodate hanger straps and rods, and enable the same to besecured in supporting relation by bending or enlarging the ends thereofwhich are passed through the apertures 13y.

As shown in FIGS. 3, 5 & 7 rectangularly shaped heavy chassis frameportions designated as entireties by the letter H, are provided inwidely spaced, outwardly disposed relation to accommodate the two setsof supporting wheels W for the mobile Chassis, and to further strengthenthe chassis, including the connection of the floor system and oblongframes H with the axle housings and springs of the chassis. The heavyoblong frames I-I may be constructed of I-beams or I-I-beams weldedtogether in rectangular formation and interconnected at forward andrearward ends by welding or the like to the heavy longitudinal framebeams 10 previously described.

As shown in FIG. 3 depending, heavy bolsters 19 are welded or ifdesired, pivotally secured to the lower heavy webs of the I-beamsconstituting the rectangular frame structure H for surrounding thewheels W. Springs 20, broken away in part (FIG. 3) are pivotallyconnected at their upper converging ends to clevis bolt or shackle 19aand in conventional manner not shown, are connected with an axle or axlehousing extending transversely of the system and to which the wheels arerotatably connected.

FIGS. 5, 6 and 7 illustrate the provision with use of the longitudinallyextending webs and sections 17 of longitudinal air ducts for return ofair for heating or air conditioning. The arrows indicate flow directionand in the forced draft of air from a heater, furnace or the like, theheated or air conditioned air passes forwardly through the numerousplenums formed by the webbed cross spanning sections 13 with theintercommunicating large circular passages 13x.

In FIG. 7 one half of a large mobile home is illustrated in verticalsection, having the outer side walls S insulated by joists 21 as shown,and having thereon a roof section R. Registers 22 as shown in FIG. 5,having open work grills 22a communicate at spaced intervalslongitudinally of the floor system with the interior of the housing. Theinterior longitudinal wall W as shown in FIG. 7 is of double plystructure to provide insulation and adjacent or at the lower edgethereof, return entrances 23 are provided with suitable grills 23a.

From the foregoing description it will be seen that I have provided avery strong, integrated floor and chassis system forming with thelongitudinal light gauge zeebars or equivalent web sections, traversingthe multiplicity of cross sections 13 a multi-cellular covered andsealed at top and bottom by the upper flooring horizontal partition 16and the lower hard plastic horizontal partition 15.

It will further be seen that the integrated cellular construction makesprovisionfor a plurality of transverse plenums therein, interconnectedwith several sets of aligned communication apertures for intake flow ofheating or cooling air; and further provides at the medial portions ofthe floor system dividing longitudinal sections 17 to define returnpassages or ducts. The integrated cellular structure is reinforced andspans the heavy longitudinal I-beams or perimeter frame members whichhave the dual function of constituting the longitudinal chassis frame.

The space between top flooring sections and the lower flooring plan maybe substantially reduced in height, as contrasted with conventionalflooring systems which employ wooden 2X4 rafters or the like, and theentire floor system may be built and set up upon the axles and mainchassis structure of the frame without requiring the inversion of aseparate chassis frame as is now utilized conventionally and generallyin mobile homes.

It will further be seen, from the foregoing description in connectionwith the accompanying drawings, that I have conceived a new method forproduction of an integrated and balanced floor system with heavy supportfor chassis use or foundation ofa modular housing unit. This methodconsists essentially in forming a multicellular body having a pair ofrelatively heavy metal beams disposed as perimeter longitudinal floorframes and also as the main frame members of a modular unit or chassis.In such method of cellular construction I utilize a plurality ofrelatively light gauge flanged transverse sections (such as zee bars)spanning said heavy metal beams and said cellular body. I also employ aplurality of similarly webbed and flanged longitudinal sections crossingsaid first mentioned transverse section and in addition to reinforcing,also dividing the cellular structure longitudinally of the overall body.My method further includes the pre-forming in said transverse flangesections of a plurality of sets of communicating apertures. The methodis further characterized by forming a bottom sealed closure for thecellular structure through the medium of a layer of hard (preferablyfoamed) plastic material, such as urethane, in which the lower flangesof the transverse sections and also the longitudinal thin sections areembedded; and lastly, forming an upper covering for the cellularstructure by a stratum of flooring material secured upon the upperflanges of the transverse and longitudinal flanged sections.

What is claimed is:

1. An integrated and balanced chassis and floor system for mobile homesand the like having in combination,

a pair of relatively heavy, elongate flanged frame beams constitutingthe main beams of the chassis and also the perimeter frame of the floorsystem,

a multiplicity of comparatively light spacing and reinforcing sectionstransversely interconnecting said beams and having vertically disposedintermediate webs and upper and lower angular flanges,

a bottom floor partition sealing and integrally connecting saidreinforcing transverse sections with said longitudinal frame beams andcomprising a stratum of strong plastic material in which the lowerflanges of said transverse sections are embedded,

an upper floor partition covering and connecting the upper flanges ofsaid transverse reinforcing sections and also interconnected at thelongitudinal edges thereof with said pair of heavy frame beams, and vsaid transverse sections having at least one set of substantiallyaligned, relatively large apertures formed therein forintercommunicating transverse plenums formed within said flooringsystem, and for also accommodating conduits disposed longitudinally ofsaid system.

2. The structure and combination set forth in claim 1 furthercharacterized by at least one longitudinal flanged section generallysimilar in construction to said transverse sections and transversingsaid transverse sections and sealed at upper and lower flanged portionswith said lower plastic stratum and with said flooring upper section,and disposed inthe medial longitudinal portion of said system to furtherreinforce the structure, and in addition to divide the interior intolongitudinal lanes.

3. The structure set forth in claim 2 wherein a plurality of saidlongitudinal flanged sections are employed traversing said transversesections and disposed in the medial longitudinal portion of said system,defining with the cooperation of sets of aligned communication aperturesin the medial webs of the transverse reinfording sections a lane or ductfor return of temperatureconditioning air.

4. The structure and combination set forth in claim 1 furthercharacterized by means in the intermediate webs of said transversereinforcing sections, adjacent the upper portion of said apertures forretaining hanger elements for supporting and positioning conduits whichextend longitudinally of said system and through certain of saidapertures.

5. The structure and combination set forth in claim 1 and a pair ofrigid rectangular frames constructed of metal beams disposed intransverse alignment in the rear and side portions of the assembly forencompassing running gear including wheels of the chassis and forconnection with the running gear of the chassis,

said rectangular frames constituting also a part of the integrated floorsystem and further reinforcing the same.

6. The structure and combination set forth in claim 1 and thin sheetpartition media supported by the lower flanges of said transverselydisposed reinforcing sections,

and said stratum of plastic material being laid up upon said sheets andfoamed thereon.

7. The structure and combination set forth in claim 6 wherein saidplastic stratum continues along its longitudinal edges upwardly againstthe inner medial webs of said heavy flanged frame beams.

8. An integrated and balanced chassis and floor system for mobile homesand the like having in combination,

a pair of relatively heavy, elongate flanged frame beams constitutingthe main beams of the chassis and also the perimeter frame of the floorsystem,

a multiplicity of comparatively light, spacing and reinforcing sectionstransversely interconnecting said beams and having vertically disposedcontinuous intermediate webs and upper and lower angular flanges,

a continuous bottom floor partition integrally connally of said system.

1. An integrated and balanced chassis and floor system for mobile homesand the like having in combination, a pair of relatively heavy, elongateflanged frame beams constituting the main beams of the chassis and alsothe perimeter frame of the floor system, a multiplicity of comparativelylight spacing and reinforcing sections transversely interconnecting saidbeams and having vertically disposed intermediate webs and upper andlower angular flanges, a bottom floor partition sealing and integrallyconnecting said reinforcing transverse sections with said longitudinalframe beams and comprising a stratum of strong plastic material in whichthe lower flanges of said transverse sections are eMbedded, an upperfloor partition covering and connecting the upper flanges of saidtransverse reinforcing sections and also interconnected at thelongitudinal edges thereof with said pair of heavy frame beams, and saidtransverse sections having at least one set of substantially aligned,relatively large apertures formed therein for intercommunicatingtransverse plenums formed within said flooring system, and for alsoaccommodating conduits disposed longitudinally of said system.
 2. Thestructure and combination set forth in claim 1 further characterized byat least one longitudinal flanged section generally similar inconstruction to said transverse sections and transversing saidtransverse sections and sealed at upper and lower flanged portions withsaid lower plastic stratum and with said flooring upper section, anddisposed in the medial longitudinal portion of said system to furtherreinforce the structure, and in addition to divide the interior intolongitudinal lanes.
 3. The structure set forth in claim 2 wherein aplurality of said longitudinal flanged sections are employed traversingsaid transverse sections and disposed in the medial longitudinal portionof said system, defining with the cooperation of sets of alignedcommunication apertures in the medial webs of the transverse reinfordingsections a lane or duct for return of temperature-conditioning air. 4.The structure and combination set forth in claim 1 further characterizedby means in the intermediate webs of said transverse reinforcingsections, adjacent the upper portion of said apertures for retaininghanger elements for supporting and positioning conduits which extendlongitudinally of said system and through certain of said apertures. 5.The structure and combination set forth in claim 1 and a pair of rigidrectangular frames constructed of metal beams disposed in transversealignment in the rear and side portions of the assembly for encompassingrunning gear including wheels of the chassis and for connection with therunning gear of the chassis, said rectangular frames constituting also apart of the integrated floor system and further reinforcing the same. 6.The structure and combination set forth in claim 1 and thin sheetpartition media supported by the lower flanges of said transverselydisposed reinforcing sections, and said stratum of plastic materialbeing laid up upon said sheets and foamed thereon.
 7. The structure andcombination set forth in claim 6 wherein said plastic stratum continuesalong its longitudinal edges upwardly against the inner medial webs ofsaid heavy flanged frame beams.
 8. An integrated and balanced chassisand floor system for mobile homes and the like having in combination, apair of relatively heavy, elongate flanged frame beams constituting themain beams of the chassis and also the perimeter frame of the floorsystem, a multiplicity of comparatively light, spacing and reinforcingsections transversely interconnecting said beams and having verticallydisposed continuous intermediate webs and upper and lower angularflanges, a continuous bottom floor partition integrally connecting andreinforcing said transverse sections with said longitudinal frame beamsand forming therewith a series of transversely disposed plenums orchambers, a continuous upper floor partition covering and connecting theupper flanges of said transverse reinforcing sections and alsointerconnected at the longitudinal edges thereof with said pair of heavyframe beams, and said transverse sections having at least one set ofsubstantially aligned, relatively large apertures formed therein forintercommunicating transverse plenums formed within said flooringsystem, and for also accommodating conduits disposed longitudinally ofsaid system.